US11898060B2 - Anti-corrosive zinc primer coating compositions - Google Patents

Anti-corrosive zinc primer coating compositions Download PDF

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Publication number
US11898060B2
US11898060B2 US15/122,469 US201515122469A US11898060B2 US 11898060 B2 US11898060 B2 US 11898060B2 US 201515122469 A US201515122469 A US 201515122469A US 11898060 B2 US11898060 B2 US 11898060B2
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coating composition
microspheres
epoxy
silicate
zinc
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US20170066928A1 (en
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Maria Bilurbina CAMPS
Andreas Lundtang Paulsen
Josep Palasi BARGALLO
Tereza Vostracká
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Hempel AS
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Hempel AS
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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/08—Anti-corrosive paints
    • C09D5/10—Anti-corrosive paints containing metal dust
    • C09D5/106—Anti-corrosive paints containing metal dust containing Zn
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L9/00—Compositions of homopolymers or copolymers of conjugated diene hydrocarbons
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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    • C08K3/02—Elements
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • C08K3/36—Silica
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08L63/00—Compositions of epoxy resins; Compositions of derivatives of epoxy resins
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
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    • C08L83/00—Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
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    • C09D1/00—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
    • C09D1/02—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances alkali metal silicates
    • C09D1/04—Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances alkali metal silicates with organic additives
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    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D177/00—Coating compositions based on polyamides obtained by reactions forming a carboxylic amide link in the main chain; Coating compositions based on derivatives of such polymers
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    • C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
    • C09D183/04—Polysiloxanes
    • C—CHEMISTRY; METALLURGY
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    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D201/00—Coating compositions based on unspecified macromolecular compounds
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    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/08—Anti-corrosive paints
    • C09D5/10—Anti-corrosive paints containing metal dust
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    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/20—Diluents or solvents
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    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
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    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/48—Stabilisers against degradation by oxygen, light or heat
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    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/61—Additives non-macromolecular inorganic
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    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
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    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/70—Additives characterised by shape, e.g. fibres, flakes or microspheres
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/02—Elements
    • C08K3/08—Metals
    • C08K2003/0893—Zinc
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/20—Oxides; Hydroxides
    • C08K3/22—Oxides; Hydroxides of metals
    • C08K2003/2227—Oxides; Hydroxides of metals of aluminium
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    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/16—Solid spheres
    • C08K7/18—Solid spheres inorganic
    • C08K7/20—Glass

Definitions

  • the present invention resides in the field of anti-corrosive coating compositions, in particular coating compositions for protecting iron and steel structures.
  • the present invention relates to coating compositions comprising particulate zinc, conductive pigments, and microspheres.
  • Zinc primers both organic and in-organic coatings, are extensively used in the marine and offshore industry and may also be specified for e.g. bridges, containers, refineries, petrochemical industry, power-plants, storage tanks, cranes, windmills and steel structures part of civil structures e.g. airports, stadia, tall buildings.
  • Such coatings may be based on a number of binder systems, such as binder systems based on silicates, epoxy, polyurethanes, cyclized rubbers, phenoxy resin, epoxy ester, urethane alkyd etc.
  • zinc primers zinc is used as a conductive pigment to produce an anodically active coating.
  • Zinc acts as sacrificial anodic material and protects the steel substrate, which becomes the cathode.
  • the resistance to corrosion is dependent on the transfer of galvanic current by the zinc primer but as long as the conductivity in the system is preserved and as long there is sufficient zinc to act as anode the steel will be protected galvanically. Therefore, zinc pigment particles in zinc primers are packed closely together and zinc primers are typically formulated with very high loadings of zinc powder.
  • U.S. Pat. No. 4,621,024 discloses coating microspheres with a metal substrate, such as zinc, resulting in an overall reduction in the metal component of the coating.
  • U.S. Pat. No. 5,252,632 discloses the use of non-coated hollow glass microspheres for improving the corrosion protection of zinc-based coating compositions, as well as decreasing the density of the composition.
  • U.S. Pat. No. 6,287,372 discloses further efforts to reduce the amount of zinc dust in the compositions by incorporation of ceramic microspheres. It is further disclosed that the incorporation of ceramic microspheres facilitates thicker coatings without mud cracking.
  • WO 2008/125610 discloses the inclusion of certain zinc alloys for improving the corrosion protection of coating compositions. It is further disclosed that conductive pigments, such as carbon black, may improve corrosion inhibition.
  • WO 96/29372 discloses dry coating compositions for dissolving in a solvent in situ, said dry coating compositions containing graphite to avoid hard settling of the coating compositions.
  • WO 99/58274 discloses a coating composition containing carbon-modified zinc dust, zinc dust, and hollow glass spheres in an epoxy ester resin base.
  • the carbon-modified zinc dust is not a simple mixture of carbon and zinc.
  • the object of the invention is achieved with a coating composition
  • a coating composition comprising:
  • the coating composition according to the present invention said microspheres are not hollow glass microspheres.
  • the binder system may be selected from epoxy-based binder systems, silicate-based binder systems, polysiloxane-based binder systems, polyurethane-based binder systems, cyclized rubber-based binder systems, and phenoxy resin-based binder systems.
  • the addition of zinc, microspheres, and conductive pigment is beneficial to each of these binder systems. However, the effect may be more pronounced in some of the binder systems.
  • the binder system selected from epoxy-based binder systems, polysiloxane-based binder systems, polyurethane-based binder systems, cyclized rubber-based binder systems, and phenoxy resin-based binder systems.
  • the binder system is selected from epoxy-based binder systems, silicate-based binder systems, polysiloxane-based binder systems, and polyurethane-based binder systems.
  • the binder system is selected from epoxy-based binder systems, polysiloxane-based binder systems, and polyurethane-based binder systems.
  • the binder system is a silicate-based binder system.
  • the binder system is an epoxy-based binder system
  • the coating composition according to the invention may comprise other paint constituents as will be apparent for the person skilled in the art.
  • coating constituents are pigments, fillers, additives (e.g. surfactants, wetting agents and dispersants, defoaming agents, catalysts, stabilizers, coalescing agents, thixothropic agents (such as polyamide waxes), anti-settling agents and dyes).
  • the coating composition typically comprises a solvent or solvents, as will be apparent for the person skilled in the art.
  • solvents are alcohols, such as methanol, ethanol, propanol, isopropanol, butanol, isobutanol and benzyl alcohol; aliphatic, cycloaliphatic and aromatic hydrocarbons, such as white spirit, cyclohexane, toluene, xylene and naphtha solvent; ketones, such as methyl ethyl ketone, acetone, methyl isobutyl ketone, methyl isoamyl ketone, diacetone alcohol and cyclo-hexanone; ether alcohols, such as 2-butoxyethanol, propylene glycol monomethyl ether and butyl diglycol; esters, such as methoxypropyl acetate, n-butyl acetate and 2-ethoxyethyl acetate; and mixtures thereof.
  • the coating composition may comprise an accelerator, as will be apparent for the person skilled in the art.
  • accelerators include zinc chloride, magnesium chloride, dibutyltin laurate, and dioctyltin laurate.
  • the coating composition typically comprises fillers, as will be apparent for the person skilled in the art.
  • fillers include red or yellow iron oxides, natural and precipitated barium sulphate, barytes, blanc fixe; aluminium silicate, kaolin, kaolinite, china clay; magnesium silicate and magnesium hydrosilicate, mica, talc, micaceous iron oxide, chlorite, tremolite; silica, surface treated silica, amorphous quartz, crystalline quartz, fumed silica; aluminium oxide, bauxite, calcined bauxite; calcium magnesium carbonate, dolomite; natural and precipitated calcium carbonate; aluminium silicates, potassium/aluminium silicates, feldspar; nepheline syenite; calcium silicates, wollastonite; zinc oxide; zinc phosphate; bismuth vanadate; silicon carbide; zeolites; pyrophyllite.
  • other families of sulphates, carbonates, silicate
  • epoxy-based binder system should be construed as the combination of one or more epoxy resins, any curing agents, any reactive epoxy diluents, any epoxy modifiers, any extender resins, any epoxy accelerators, and any epoxy flexibilizers.
  • Suitable reactive epoxy diluents comprise e.g. mono functional glycidyl ethers or esters of aliphatic, cycloaliphatic or aromatic compounds, e.g. Araldite DY-E/BD, ex. Huntsman Advanced Materials—Germany, Cardolite NC 513, ex. Cardanol Chemicals (US) and Cardura E10P ex. Momentive—Netherlands.
  • suitable epoxy modifiers comprise e.g. oils, oil derivatives, modified oils such as linseed oil and derivatives thereof, castor oil and derivatives thereof, soy bean oil and derivatives thereof.
  • Suitable extender resins comprise e.g. saturated polyester resins, polyvinylacetate, polyvinylbutyrate, copolymers of vinyl acetate and vinyl isobutyl ether, copolymers of vinyl chloride and vinyl isobutyl ether, of polyvinyl methyl ether, polyvinyl isobutyl ether, polyvinyl ethyl ether, modified aromatic hydrocarbon resins; styrene copolymers such as styrene/butadiene copolymers; acrylic resins; hydroxy-acrylate copolymers; fatty acids; and cyclized rubbers.
  • saturated polyester resins polyvinylacetate, polyvinylbutyrate, copolymers of vinyl acetate and vinyl isobutyl ether, copolymers of vinyl chloride and vinyl isobutyl ether, of polyvinyl methyl ether, polyvinyl isobutyl ether, polyvinyl ethyl ether, modified
  • the epoxy-based binder system may comprise one or more epoxy resins selected from aromatic or non-aromatic epoxy resins (e.g. hydrogenated epoxy resins), containing more than one epoxy group per molecule, which is placed internally, terminally, or on a cyclic structure, together with any suitable curing agent to act as cross-linking agent.
  • aromatic or non-aromatic epoxy resins e.g. hydrogenated epoxy resins
  • any suitable curing agent to act as cross-linking agent e.g. hydrogenated epoxy resins
  • Combinations with reactive epoxy diluents such as from the classes mono functional glycidyl ethers or esters of aliphatic, cycloaliphatic or aromatic compounds can be included in order to reduce viscosity and for improved application and physical properties.
  • Suitable epoxy-based binder systems are believed to include epoxy and modified epoxy resins selected from bisphenol A, bisphenol F, Novolac epoxies, non-aromatic epoxies, cycloaliphatic epoxies, epoxidised polysulfides, and epoxy functional acrylics or any combinations hereof.
  • a particular epoxy-based binder system includes bisphenol A.
  • Epoxy-based binder systems may be of the conventional type, such as solvent borne and water-borne epoxy resin based. Examples of suitable commercially available solvent-borne epoxy resins are:
  • Araldite GZ 7071X75BD ex. Huntsman Advanced Materials (Germany), bisphenol A type in xylene
  • the epoxy-based binder system may comprise one or more curing agents selected from compounds or polymers comprising at least two reactive hydrogen atoms linked to nitrogen.
  • Suitable curing agents for solvent-borne epoxy resins are believed to include amines or amino functional polymers selected from aliphatic amines and polyamines (e.g. cycloaliphatic amines and polyamines), polyamidoamines, polyoxyalkylene amines (e.g. polyoxyalkylene diamines), aminated polyalkoxyethers (e.g. those sold commercially as “Jeffamines”), alkylene amines (e.g. alkylene diamines), aralkylamines, aromatic amines, Mannich bases (e.g. those sold commercially as “phenalkamines”), amino functional silicones or silanes, isocyanates, and including amine adducts and derivatives thereof.
  • the curing agents are polyamidoamines.
  • Epoxy hardener MXDA Ex. Mitsubishi Gas Chemical Company Inc (USA), aralkyl amine
  • Suitable curing agents for water-borne epoxy resins may include amine adducts.
  • amine adducts examples of suitably commercially available amine adducts are:
  • epoxy-based binder systems comprise a) one or more epoxy resins selected from bisphenol A, bisphenol F and Novolac; and b) one or more curing agents selected from Mannich Bases, polyamidoamines, polyoxyalkylene amines, alkylene amines, aralkylamines, polyamines, and adducts and derivatives thereof.
  • epoxy-based binder systems may comprise both bisphenol A and polyamidoamines.
  • the epoxy resin may have an epoxy equivalent weight of 100-9000, 100-2000, such as 100-1500 e.g. 150-1000, such as 150-700.
  • epoxy-based binder systems may comprise one or more bisphenol A epoxy resins having an epoxy equivalent weight of 150-700 and one or more polyamidoamine or adducts and derivatives thereof.
  • the total amount of epoxy resin may be in the range 10 to 50% by solids volume, such as in the range 15 to 40% by solids volume, e.g. in the range 18 to 35% by solids volume.
  • epoxy-based binder systems are ambient curing binder systems, e.g. an epoxy-based binder system curing at a temperature in the range of ⁇ 30 to 50° C., such as ⁇ 20 to 45° C.
  • the composition will form a suitable film without the addition of a curing agent. Hence, in another embodiment no curing agent is added to the paint composition.
  • the total amount of epoxy-based binder system may in one embodiment be in the range of 15-80%, such as 20-65%, e.g. 25-50%, by solids volume of the coating composition.
  • hydrogen equivalents is intended to cover only reactive hydrogen atoms linked to nitrogen.
  • the number of “hydrogen equivalents” in relation to the one or more curing agents is the sum of the contribution from each of the one or more curing agents.
  • the contribution from each of the one or more curing agents to the hydrogen equivalents is defined as grams of the curing agent divided by the hydrogen equivalent weight of the curing agent, where the hydrogen equivalent weight of the curing agent is determined as: grams of the curing agent equivalent to 1 mol of active hydrogen.
  • grams of the curing agent divided by the hydrogen equivalent weight of the curing agent is determined as: grams of the curing agent equivalent to 1 mol of active hydrogen.
  • the number of “epoxy equivalents” in relation to the one or more epoxy resins is the sum of the contribution from each of the one or more epoxy resins.
  • the contribution from each of the one or more epoxy resins to the epoxy equivalents is defined as grams of the epoxy resin divided by the epoxy equivalent weight of the epoxy resin, where the epoxy equivalent weight of the epoxy resin is determined as: grams of the epoxy resin equivalent to 1 mol of epoxy groups.
  • grams of the epoxy resin divided by the epoxy equivalent weight of the epoxy resin is determined as: grams of the epoxy resin equivalent to 1 mol of epoxy groups.
  • the ratio between the hydrogen equivalents of the one or more curing agents and the epoxy equivalents of the one or more epoxy resins may be in the range of 20:100 to 120:100, such as in the range 60:100 to 110:100 or 70:100 to 100:110, or such as 80:100 to 110:100.
  • polysiloxane-based binder system should be construed as a binder system comprising at least one curable, polysiloxane modified constituent, wherein a major part of the binder system consists of polysiloxane moieties, i.e. at least 20% by volume solids, such as at least 25% by volume solids, preferably at least 35% by volume solids, e.g. more than 50% by volume solids, of the binder system is represented by polysiloxane moieties.
  • the polysiloxane moiety should be construed to include any pendant organic substituents, such as alkyl-, phenyl-, and/or saturated cyclic structures and may also comprise curable substituents, examples hereof are alkoxy groups, unsaturated acrylic groups etc.
  • the polysiloxane-based binder system is a combination of one or more amino-functional silicone modified compound(s), one or more epoxy resins, any polysiloxane binder or polysiloxane modified binder constituent, any aminosilanes, any reactive diluents, any modifiers, any extender resins, any accelerators, and any flexibilizers.
  • amino-functional silicone modified compound is to be understood in the conventional sense, i.e. a silicone compound, e.g. a silane or polysiloxane compound, having pendant and/or terminal amino groups.
  • a silicone compound e.g. a silane or polysiloxane compound
  • amino-functional silicone compounds are amino-functional polysiloxanes and aminosilanes.
  • amino-functional silicone compound(s) is/are amino-functional polysiloxane(s).
  • amino-functional polysiloxane means a linear or branched polymeric constituent having one or more polysiloxane blocks and having pendant and/or terminal amino-functionalities.
  • the amino functionalities may, e.g., be introduced to the reactive polysiloxane by means of an aminosilane (i.e. an aminosilane such as those defined below), cf. U.S. Pat. No. 4,857,608. It should also be understood that the amino-functional polysiloxane may be prepared in situ. In some examples, a hydroxyl-functional or alkoxy-functional polysiloxane is reacted with an aminosilane whereby amino-functionalities are introduced.
  • an aminosilane i.e. an aminosilane such as those defined below
  • an aminosilane can be reacted with an ⁇ , ⁇ -dihydroxypolydimethylsiloxane at a temperature in the range of 20-80° C., preferably using 0.4-5.0 alkoxy groups of the aminosilane per silanol group of the polysiloxane. If an excess of aminosilane is used, or if the reaction is not allowed to proceed to completion, a small amount of aminosilane may remain in the product.
  • at least one amino-functional polysiloxane is the reaction product of a polysiloxane and an aminosilane.
  • amino-functional polysiloxanes examples include ⁇ , ⁇ -diamino-functional polysiloxanes (e.g. polysiloxane fluids).
  • Illustrative examples of commercially available amino-functional polysiloxanes are SILRES HP 2000 (amino-functionalised methyl-phenyl silicone) ex Wacker Chemie—Germany; SF1708 (Amino functionalised polysiloxane fluid) ex General Electric Co.; etc.
  • the amino-functional silicon compound(s) is/are aminosilane(s).
  • a polysiloxane binder or polysiloxane modified binder constituent acting as a reactive flexibiliser/co-binder is preferably present.
  • Aminosilanes are frequently defined as silanes of the formula: (RO) x R 3 ⁇ x SiR 1 NHR 2 wherein each R independently is selected from C 1-8 -alkyl (e.g. methyl, ethyl, hexyl, octyl, etc.), C 1-4 -alkyl-O—C 2-4 -alkyl; aryl (e.g.
  • R 1 is selected from —(CH 2 ) 2-4 —, methyl-substituted trimethylene, and —(CH 2 ) 2-3 —O—(CH 2 ) 2-3 ;
  • R 2 is selected from hydrogen and —(CH 2 ) 2-4 —NH 2 ;
  • x is an integer from 0-3 such as 0, 1, 2 or 3.
  • aminosilanes are (CH 3 O) 3 Si(CH 2 ) 3 NH(CH 2 ) 2 NH 2 ; (CH 3 CH 2 OCH 2 CH 2 O) 3 Si(CH 2 ) 2 NH 2 ; (C 2 H 5 O) 3 Si(CH 2 ) 3 NH 2 ; (CH 3 OCH 2 CH 2 O) 3 Si(CH 2 ) 3 NH 2 ; (C 2 H 5 O) 3 Si(CH 2 ) 3 O(CH 2 ) 3 NH 2 ; (C 2 H 5 O) 2 C 6 H 5 Si(CH 2 ) 3 NH 2 ; (C 2 H 5 O) 3 SiCH 2 O(CH 2 ) 2 NH 2 ; (C 2 H 5 O) 3 Si(CH 2 ) 3 O(CH 2 ) 2 NH 2 ; and (C 2 H 5 O) 2 CH 3 Si(CH 2 ) 3 NH 2 .
  • Illustrative examples of commercially available aminosilanes are Dynasilan AMEO (3-aminopropyltriethoxysilane) ex Degussa Hüls; KBM603 (N- ⁇ -aminoethyl- ⁇ -aminopropyltrimethoxysilane) ex Shin Etsu; etc.
  • polysiloxane binder or polysiloxane modified binder examples include polysiloxanes having the formula:
  • each R 1 is independently selected from C 1-6 -alkyl (e.g. methyl, ethyl, etc.); C 1-6 -hydroxyalkyl (e.g. hydroxymethyl, hydroxyethyl etc.); C 1-6 -alkoxy (e.g. methoxy, ethoxy, propoxy etc.) and each R 2 is independently selected from silanol, C 1-6 -alkyl (e.g. methyl, ethyl, etc.); C 1-6 -hydroxyalkyl (e.g. hydroxymethyl, hydroxyethyl etc.); C 1-6 -alkoxy(e.g. methoxy, ethoxy, propoxy etc.).
  • the polysiloxane binder or polysiloxane modified binder is a polysiloxane binder including methoxy groups.
  • the amino-functional silicon compound(s) is/are the combination of amino-functional polysiloxane(s) and aminosilane(s), i.e. the binder phase comprises one or more amino-functional polysiloxanes as well as one or more aminosilane(s).
  • This combination can be accomplished by adding an amino-functional polysiloxane (as described above) and an aminosilane (as defined above), or by using a reaction product between an aminosilane and a polysiloxane in which a portion of the aminosilane remains unreacted.
  • the “one or more epoxy resins” are similar to the epoxy resins described under the epoxy-based binder system section above.
  • polyurethane-binder system is intended to mean a binder system having as the primary components one or more di- or poly-isocyanate components and a hydroxy functional component containing two or more hydroxyl groups (two component systems) or having as the primary components one or more isocyanate prepolymers (typically one component systems).
  • One type of polyurethane-based binder system contains
  • a hydroxy functional component comprising at least two hydroxyl groups
  • the cross-linking which takes place is based on a reaction between poly-isocyanate component a) and hydroxyl functional component b).
  • Suitable poly-isocyanates for use as poly-isocyanate component a) in the composition include the known poly-isocyanates of polyurethane chemistry.
  • suitable low molecular weight poly-isocyanates having a molecular weight of 168 to 300 include hexamethylene diisocyanate (HDI), 2,2,4- and/or 2,4,4-trimethyl-1,6-hexamethylene diisocyanate, dodecamethylene diisocyanate, 2,4-diisocyanato-1-methyl-benzene (toluene diisocyanate, TDI), 2,4-diisocyanato-1-methylbenzene, 1,4-diisocyanatocyclohexane, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane (IPDI), 2,4′- and/or 4,4′-diisocyanato-dicyclohexyl methane, 2,4- and/or
  • the one or more polyisocyanates are selected from aliphatic polyisocyanates, e.g. hexamethylene diisocyanate (HDI), 2,2,4- and/or 2,4,4-trimethyl-1,6-hexamethylene diisocyanate, dodecamethylene diisocyanate, 1,4-diisocyanatocyclohexane, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane (IPDI), 2,4′- and/or 4,4′-diisocyanato-dicyclohexyl methane, and 2,4- and/or 4,4′-diisocyanato-diphenyl methane.
  • HDI hexamethylene diisocyanate
  • IPDI 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane
  • IPDI 2,4′- and/or 4,4′-diisocyanato-
  • the coating composition also comprises one or more catalysts, e.g. one or more selected from tetramethylbutanediamine (TMBDA), N-alkyl morpholines, triethylamine (TEA), 1,8-diazabicyclo[5.4.0]undecene-7 (DBU), pentamethyldiethylene-triamine (PMDETA), zinc octoate, dioctyltin dilaurate dibutyltin dilaurate, and dibutyltin oxide, in particular from dioctyltin dilaurate dibutyltin dilaurate, and dibutyltin oxide.
  • the coating composition is devoid of any such catalysts.
  • the one or more polyisocyanates are selected from aromatic polyisocyanates, e.g. 2,4-diisocyanato-1-methyl-benzene (toluene diisocyanate, TDI), 2,4-diisocyanato-1-methyl-benzene and mixtures of these isomers with their higher homologues which are obtained in known manner by the phosgenation of aniline/formaldehyde condensates, 2,4- and/or 2,6-diisocyanatotoluene and any mixtures of these compounds.
  • aromatic polyisocyanates e.g. 2,4-diisocyanato-1-methyl-benzene (toluene diisocyanate, TDI), 2,4-diisocyanato-1-methyl-benzene and mixtures of these isomers with their higher homologues which are obtained in known manner by the phosgenation of aniline/formaldehyde condensates, 2,4- and
  • derivatives of these monomeric poly-isocyanates include poly-isocyanates containing biuret groups.
  • modified poly-isocyanates are particularly preferred: N,N′,N′′-tris-(6-isocyanatohexyl)-biuret and mixtures thereof with its higher homologues and N,N′,N′′-tris-(6-isocyanatohexyl)-isocyanurate and mixtures thereof with its higher homologues containing more than one isocyanurate ring.
  • Desmodur N3900 (formerly VP2410), ex. Bayer (Germany), aliphatic polyisocyanate
  • Isocyanate group-containing prepolymers and semi-prepolymers based on the monomeric simple or modified poly-isocyanates exemplified above and organic polyhydroxyl compounds are also preferred for use as poly-isocyanate component a).
  • These pre-polymers and semi pre-polymers generally have an isocyanate content of 0.5-30% by weight, preferably 1-20% by weight, and are prepared in known manner by the reaction of the above mentioned starting materials at an NCO/OH equivalent ratio of 1.05:1 to 10:1 preferably 1.1:1 to 3:1, this reaction being optionally followed by distillative removal of any un-reacted volatile starting poly-isocyanates still present.
  • the pre-polymers and semi pre-polymers may suitably be prepared from low molecular weight polyhydroxyl compounds having a molecular weight of 62 to 299, such as ethylene glycol, propylene glycol, trimethylol propane, 1,6-dihydroxy hexane; low molecular weight, hydroxyl-containing esters of these polyols with dicarboxylic acids of the type exemplified hereinafter; low molecular weight ethoxylation and/or propoxylation products of these polyols; and mixtures of the preceding polyvalent modified or unmodified alcohols.
  • low molecular weight polyhydroxyl compounds having a molecular weight of 62 to 299, such as ethylene glycol, propylene glycol, trimethylol propane, 1,6-dihydroxy hexane; low molecular weight, hydroxyl-containing esters of these polyols with dicarboxylic acids of the type exemplified hereinafter; low molecular weight eth
  • the pre-polymers and semi pre-polymers are, however, preferably prepared from relatively high molecular weight polyhydroxyl compounds.
  • polyhydroxyl compounds have at least two hydroxyl groups per molecule (and generally have a hydroxyl group content of 0.5-17% by weight, preferably 1-5% by weight.
  • suitable relatively high molecular weight polyhydroxyl compounds which may be used for the preparation of the pre-polymers and semi pre-polymers include the polyester polyols based on the previously described low molecular weight.
  • polyester polyols examples include:
  • Polyether polyols which are obtained in known manner by the alkoxylation of suitable starting molecules, are also suitable for the preparation of the isocyanate group-containing pre-polymers and semi pre-polymers.
  • suitable starting molecules for the polyether polyols include the previously described monomeric polyols, water, and any mixtures of these starting molecules.
  • Ethylene oxide and/or polylene oxide are particularly suitable alkylene oxides for the alkoxylation reaction. These alkylene oxides may be introduced into the alkoxylation reaction in any sequence or as a mixture.
  • polyether polyols examples include:
  • Desmophen 1380 BT 03/2008 previously Desmophen 550 U
  • Bayer Material Science Germany
  • hydroxyl group-containing polycarbonates which may be prepared by the reaction of the previously described monomeric diols with phosgene and diaryl carbonates such as diphenyl carbonate.
  • Component b) is based in whole or in part on organic polyhydroxyl compounds known from polyurethane chemistry and includes both the low molecular weight polyhydroxyl compounds and the relatively high molecular weight polyhydroxyl compounds previously set forth for the preparation of the pre-polymers and semi pre-polymers suitable for use as poly-isocyanate component a).
  • hydroxyl functional, isocyanate-reactive, compounds which may be used as component b) are the hydroxy functional poly acrylates known for use in polyurethane coatings. These compounds are hydroxyl-containing copolymers of olefinically unsaturated compounds having a number average molecular weight (Mn) determined by vapour pressure or membrane osmometry of 800-50,000, preferably 1000-20,000 and more preferably 5000-10,000, and having a hydroxyl group content of 0.1-12% by weight, preferably 1-10% by weight and most preferably 2-6% by weight.
  • Mn number average molecular weight
  • the copolymers are based on olefinic monomers containing hydroxyl groups and olefinic monomers which are free from hydroxyl groups.
  • Suitable monomers include vinyl and vinylidene monomers such as styrene, ⁇ -methyl styrene, o- and p-chloro styrene, o-, m- and p-methyl styrene, p-tert.-butyl styrene; acrylic acid; (methy)acrylonitrile; acrylic and methacrylic acid esters of alcohols containing 1 to 8 carbon atoms such as ethyl acrylate, methyl acrylate, n- and isopropyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, iso-octyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate and iso-octyl methacrylate; diesters of fumaric acid, itaconic acid or maleic
  • components a) and b) are used in amounts sufficient to provide an equivalent ratio of isocyanate groups to isocyanate-reactive (hydroxyl) groups of 0.8:1 to 20:1, preferably 0.8:1 to 2:1, more preferably 0.8:1 to 1.5:1, even more preferably 0.8:1 to 1.2:1 and most preferably about 1:1.
  • Suitable commercially available hydroxyl functional (isocyanate-reactive) resins include:
  • a polyurethane coating system of the type descripted above is typically supplied as a two-component system, where one package comprise the hydroxyl-containing component(s), any pigments, solvents and additives and another package comprise the polyisocyanate-containing compound and moisture free solvents. Zinc particles, conductive pigment(s) and microspheres are typically added to the hydroxyl containing package.
  • Another type of polyurethane coating systems is a one-component system, where all components are supplied in the same container and the paint is moisture-cured (typically at ambient temperature and ambient conditions or under slightly increased temperatures e.g. 60-100°, optionally with the presence of an accelerator e.g. a tin comprising accelerator.
  • an accelerator e.g. a tin comprising accelerator.
  • the moisture cured polyurethane-based binder system contains one or more isocyanate prepolymers e.g. polyisocyanate prepolymer based on toluene diisocyanate (TDI).
  • isocyanate prepolymers e.g. polyisocyanate prepolymer based on toluene diisocyanate (TDI).
  • a polyurethane coating system of the type described above is typically supplied as a one-component system, where the package comprise the one or more isocyanate prepolymers, conductive pigment(s), zinc particles, microspheres and any non-conductive pigments, fillers, solvents, additives etc.
  • Zinc silicate coatings are used mainly as anti-corrosive primers on steel substrates due to outstanding corrosion resistance, superior mechanical properties, very high temperature resistance and excellent chemical resistance.
  • Zinc silicates are superior to other linings concerning anticorrosive properties due to its function as a sacrificial anode applied directly on top of the clean steel surface. When the coating layer is damaged, the zinc will protect the damage by galvanic protection. The function is similar to that of galvanized steel.
  • Zinc silicate-based coatings are normally used as primers, i.e. first coating layer in a multiple coat system with subsequent layers of suitable generic types of coatings, e.g. epoxy or epoxy+polyurethane. However, zinc silicate coatings can also be used as one-coat systems.
  • Zinc silicate coatings are typically one or two component systems. These coatings typically do not require the addition of a curing agent. In two component systems the zinc particles are stored separately from the rest of the coating components. Zinc silicate coatings may also be three component systems, wherein the accelerator and zinc particles are usually stored separately from the rest of the components.
  • Zinc silicate coatings may be applied with standard spraying equipment. However, spraying a silicate paint composition is a little different from conventional paints. Normally, paints have a tendency to build up in corners on welding seams and in difficult accessible areas, a problem which is even more pronounced when the silicate paint composition contains zinc. These products are formulated with PVC above the CPVC ratio to ensure sufficient contact between the zinc particles for galvanic protection. Silicate coatings with zinc will therefore have a higher risk for mud cracking if they are applied in too high film thickness. Consequently, extra efforts and man hours are often spent here in order not to end up with too high dry film thicknesses.
  • Silicate coatings contain silicate resins and may be either solvent-based or water-based. Accordingly, in one embodiment, the silicate-based binder system is solvent-based. In another embodiment, the silicate-based binder system is water-based.
  • the amount of silicate resin in the coating may vary. In one embodiment, the amount of silicate resin is from about 2 to 25% or 2 to 20% by solids volume, such as from about 4 to about 18% by solids volume, e.g. from about 5 to 15% or 17% by solids volume.
  • silicate binder system should be construed as the combination of—as the principal constituents—one or more silicate resins, any catalysts and any accelerators and any solvent(s).
  • Typical zinc silicate coatings for corrosion protection are solvent-based silicate coatings, such as alkyl silicate coatings.
  • the silicate-based binder system is a solvent-based silicate-based binder system.
  • the silicate-based binder system is an alkyl silicate binder system.
  • alkyl silicate binder system should be construed as the combination of—as the principal constituents—one or more alkyl silicate resins, any catalysts and any accelerators and any solvent(s).
  • the compositions may further include other constituents as it will be explained further below.
  • Suitable alkyl silicate resins include ethyl silicates although other alkyl silicates wherein the alkyl groups contains from 1 to 8 carbon atoms, such as methyl silicates, propyl silicates, butyl silicates, hexyl silicates and octyl silicates can also be employed, either alone or in admixture.
  • the alkyl silicate resins used can suitably be hydrolysed to various degrees.
  • the amount of alkyl silicate resin in the coating may vary. In one embodiment, the amount of alkyl silicate resin is from about 2 to 25% or 2 to 20% by solids volume, such as from about 4 to about 18% by solids volume, e.g. from about 5 to 15% or 17% by solids volume.
  • alkyl silicate binder systems the silicate is partially hydrolysed by means of water and by utilizing an acid (e.g. hydrochloric acid or sulphuric acid) or base as a catalyst.
  • Acid catalysis generally proceeds in a somewhat slower and more controlled fashion compared to partial hydrolysis by using a base as the catalyst.
  • the presence of acids tends to stabilize reactive silanol (Si—OH) groups and increase storage stability.
  • the zinc alkyl silicate coating compositions of the present invention should preferably facilitate fast curing, it is also relevant that the zinc alkyl silicate coating compositions are somewhat flexible upon application.
  • Ethyl silicate has been the dominant alkyl silicate resin for more than 30 years.
  • Other alkyl types have been used, such as isopropyl and butyl from which the corresponding alcohol is evolved on hydrolysis, but ethyl, despite of the low flash point of 10° C. of ethanol, is the principal type used.
  • the silicate-based binder system comprises an ethyl silicate resin.
  • Ethanol is completely miscible with water, ideal for hydrolysis and has low toxicity (G. J. Biddle, Inorganic zinc silicate coatings). Moreover, curing speed is faster than with higher alcohols.
  • the starting point for ethyl silicate (relevant illustrative example of an alkyl silicate) is tetra ethyl ortho silicate (TEOS), a monomeric product with a composition of (C 2 H 5 O) 4 Si.
  • TEOS tetra ethyl ortho silicate
  • the raw material normally used by paint manufacturers is a polyethyl silicate containing about 40% silica. Normal procedure is to partially hydrolyse the polyethyl silicate during production by addition of water and a small amount of catalyst, e.g.
  • hydrochloric acid to speed up the curing of the coating after application.
  • some of the ethoxy groups in the ethyl ortho silicate are replaced by hydroxyl groups, thereby liberating ethanol.
  • Some of the hydroxyl groups react with each other, giving off water and tying silicon atoms together by oxygen bridges.
  • the amounts of water and catalyst are carefully calculated and controlled to optimise the balance between shelf life, mixed pot life, curing and cracking level.
  • the degree of pre-hydrolysis of the alkyl silicate resin is more than 50%, such as 60-95%, e.g. 75-90%.
  • Co-binders such as cellulose and polyvinyl butyral (PVB) may be added.
  • a common way to reduce the curing time is to add an accelerator such as zinc chloride or magnesium chloride.
  • an accelerator such as zinc chloride or magnesium chloride.
  • Other possible accelerators are dibutyltin laurate and dioctyltin laurate.
  • the maximum amount of zinc chloride that can be added is limited as the fast curing has a negative impact on the cracking level (internal stress).
  • microspheres and a conductive pigment selected from the group consisting of graphite, carbon black, aluminium, black iron oxide, antimony-doped tin oxide, mica coated with antimony-doped tin oxide, carbon nanotubes, carbon fibres, and any mixture thereof to the alkyl silicate resin, the negative impact on the cracking level can be diminished and it is possible to add higher amounts of accelerator thereby reducing the curing time even further than previously possible.
  • the alkyl silicate-based binder system typically comprises one or more catalysts. Suitable catalysts are believed to include hydrochloric acid and sulphuric acid.
  • the silicate-based binder system may further comprise one or more accelerators selected from zinc chloride, magnesium chloride or borate types like trimethylborate.
  • the solvent-based zinc silicate coating composition of the invention may comprise other paint constituents as will be apparent for the person skilled in the art.
  • paint constituents are non-conductive pigments e.g. TiO 2 , yellow or red iron oxides, cobalt blue, bismuth vanadates and organic pigments; fillers, e.g. Al/K/Na silicates (e.g. Silicato MN/SA 15 12/2009. Minerals I Derivats S.A., Spain) or kaolin (e.g. Polwhite E, Imerys Performance Minerals), talc, mica, and BaSO 4 ; additives (e.g. wetting agents, dispersing agents, scavengers, rheologic agents, thickening agents, de-foaming agents, and thixotropic agents (such as bentonites/organo clay, silica aerogel)).
  • non-conductive pigments e.g. TiO 2 , yellow or red iron oxides, cobalt blue, bismut
  • the total amount of fillers and non-conductive pigments may be in the range of 0-50%, such as 0-40%, 0-30% or 0-25% by solids volume of the mixed paint composition. In the alternative, the total amount of fillers and non-conductive pigments may be in the range 5-45% or 5-40% by solids volume, such as in the range 10-35% or 30-44% by solids volume.
  • the total amount of additives may be in the range of 0-10%, such as 0.1-8% by solids volume of the mixed paint composition.
  • the coating composition of the invention contains less than 10% by weight of the filler modified CaSiO 3 , also known as “Wollastonite”.
  • the coating composition typically comprises a solvent or solvents.
  • solvents are water; alcohols, such as methanol, ethanol, propanol, isopropanol, butanol, isobutanol or benzyl alcohol; alcohol/water mixtures, such as ethanol/water mixtures; aliphatic, cycloaliphatic and aromatic hydrocarbons, such as white spirit, cyclohexane, toluene, xylene and naphtha solvent; ketones, such as methyl ethyl ketone, acetone, methyl isobutyl ketone, methyl isoamyl ketone, diacetone alcohol and cyclohexanone; ether alcohols, such as 2-butoxyethanol, propylene glycol monomethyl ether and butyl diglycol; esters, such as methoxypropyl acetate, n-butyl acetate and 2-ethoxyethyl acetate; and mixtures thereof.
  • the paint comprises solvent(s) so that the solids volume ratio percentage, SVR % (SVR—ratio between the volume of solid constituents to the total volume) is in the range of 23-100% or 25-100%, such as 30-80% or 23-80%, in particular 35-70% or 23-70% e.g. 40-65% or 23-65%.
  • SVR ratio between the volume of solid constituents to the total volume
  • SVR is determined according to ISO 3233 or ASTM D 2697 with the modification that drying is carried out at 20° C. and 60% relative humidity for 7 days instead of drying at higher temperatures.
  • said silicate coatings may also be water-based, comprising a water-based silicate-based binder system.
  • the water-based silicate-based binder system comprises one or more water-soluble silicates, such as alkali metal silicates.
  • water-soluble silicates are alkali metal silicates, such as lithium silicate, sodium silicate, or potassium silicate, and ammonium silicates, such as tetraethanol ammonium silicate, or diethanol morpholinium silicate.
  • the alkali metal silicate is lithium silicate, sodium silicate, or potassium silicate, among which lithium silicate and potassium silicate are the most preferred.
  • the paint composition may comprise fillers, accelerators and/or additives as will be apparent for the person skilled in the art.
  • fillers other than the conductive pigments as claimed herein are e.g. red or yellow iron oxides, natural and precipitated barium sulphate, barytes, blanc fixe; aluminium silicate, kaolin, kaolinite, china clay; magnesium silicate and magnesium hydrosilicate, mica, talc, micaceous iron oxide, chlorite, tremolite; silica, surface treated silica, amorphous quartz, crystalline quartz, fumed silica; aluminium oxide, bauxite, calcined bauxite; calcium magnesium carbonate, dolomite; natural and precipitated calcium carbonate; aluminium silicates, potassium/aluminium silicates, feldspar; nepheline syenite; calcium silicates, wollastonite; zinc oxide; zinc phosphate; bismuth vanadate; silicon carbide; zeolites; py
  • paint constituents are additives including thickening agents, wetting and dispersing agents.
  • suitable thickening agents are bentonite/organic clay, fumed/colloidal silica, natural thickeners (e.g. alginates), cellulosic thickeners, saccharides, and polysaccharides.
  • suitable thickening agents include bentonite/organic clay, fumed/colloidal silica, natural thickeners (e.g. alginates), cellulosic thickeners, saccharides, and polysaccharides.
  • wetting and dispersing agents that could be added include ammonium salts of polyacrylic acid, cellulose, non-ionic surfactants, anionic surfactants, and cationic surfactants.
  • accelerators include e.g. organo siliconates, alkaline borates, trimethyl borates, titanates, alcohols, colloidal silica, silanes, choline base, choline, chelates such as EDTA, iron oxide, red lead, sodium bisulphate, sodium bicarbonate, sodium dihydrogen phosphate, potassium chloride, potassium bromide, and sucrose, preferably organo siliconates such as sodium methyl siliconate, sodium ethyl siliconate, sodium propyl siliconate, potassium methyl siliconate, potassium ethyl siliconate, potassium propyl siliconate, etc.
  • organo siliconates such as sodium methyl siliconate, sodium ethyl siliconate, sodium propyl siliconate, potassium methyl siliconate, potassium ethyl siliconate, potassium propyl siliconate, etc.
  • the present invention relates to a protective coating composition
  • a protective coating composition comprising a water-based alkali metal silicate-based binder system, zinc particles, microspheres, and a conductive pigment selected from the group consisting of graphite, graphene, carbon black, aluminium, black iron oxide, antimony-doped tin oxide, indium tin oxide, mica coated with antimony-doped tin oxide, carbon nanotubes, and carbon fibres.
  • the final mixing of the components is preferably done immediately before the application of the coating onto the steel material.
  • the silicate-based binder system may also, as its main silicate component contain colloidal silica particles as described in WO 02/22746.
  • colloidal silicate An example of a suitable commercially available colloidal silicate is:
  • the zinc-containing silicate coating composition of the invention is typically prepared by mixing the silicate-based binder system, typically including already the microspheres and conductive pigment, with zinc and any other relevant constituents shortly before use thereof.
  • the constituents are typically prepared beforehand as two (or more) components (pre-mixtures), which can readily be mixed in situ so as to obtain the ready-to-use composition.
  • the material referred to as “zinc particles” is a particulate material with a high content of zinc, such as at least 90% by weight of zinc.
  • particulate material is intended to cover both fine spherical or somewhat irregularly shaped particles and other shapes such as flakes, discs, spheres, needles, platelets, fibres and rods.
  • the particulate material may be a powder or a dust.
  • particulate materials with a D 50 (mean particle size) of less than 50 ⁇ m is used.
  • a D 50 of less than 20 ⁇ m is used, in yet a further embodiment, a D 50 of less than 15 ⁇ m is used, and in a still further embodiment a D 50 of less than 12 ⁇ m is used.
  • the particle size distribution of the materials may e.g. be measured using a Helos® Sympatec GmbH laser diffraction apparatus.
  • the parameters D 50 and D 99 are equivalent particle diameters for which the volume cumulative distribution, Q3, assumes values of respectively 50 and 99%.
  • the particulate materials can be manufactured by classic gas atomization of a corresponding coarse zinc material.
  • As the particulate materials directly obtained from such a process still include coarse particles, which are incompatible with the envisaged application, a sieving or a classifying operation has to be performed.
  • the zinc particles comprised in the present invention may also be directly obtained commercially.
  • Suppliers include Purity Zinc Metals, Horsehead Corporation, Umicore, US Zinc, Jiashan Baiwei, and Garrison Minerals, among many others, e.g. ZMP 4P16 or ZMP 4P645, Umicore (Belgium).
  • the zinc particles are in one embodiment present in the coating composition of the present invention in an amount of about 0.5 to 50%, or 0.5 to 70% or 0.5 to 80% in the case of silicate-based coatings, by solids volume, such as in the amount of about 15 to 45% by solids volume, e.g. in the amount of about 18 to 40% by solids volume, especially in the amount of about 20 to 35% by solids volume of the mixed coating composition.
  • the zinc particles are present in the coating composition of the present invention in a low amount of about 0.5 to 10% by solids volume, such as in the amount of 1 to 5% by solids volume of the mixed coating composition.
  • the term “spheroidal” when used together with the term “microspheres” is meant to indicate that the microspheres are smooth, rounded, and spheroidal in shape, but allows for imperfections compared to a perfect spheroid. Some of the microspheres according to the present invention may be spheroids and most of the microspheres of the present invention are spheroid-like in their shape.
  • the terms “rounded” or “smooth, rounded” as used herein refers to the fact that even though the present microspheres may not be perfect spheroids, they do not have any sharp or angular edges.
  • microspheres of the present invention may be made from a variety of materials. These materials include glass material, ceramic material, and polymeric material.
  • microspheres does not include hollow glass microspheres.
  • the average particle size of the microspheres is partially dictated by the thickness of the protective coating to be applied to a metal surface and the size of the zinc particles. Accordingly, in one embodiment, the average particle size of the microspheres is less than the dry film thickness of the coating to be applied and larger than the average particle size of the zinc particles. In particular, if the dry film thickness of the applied coating is 50-150 ⁇ m, such as 75-150 ⁇ m, the spheres should have a D 50 of ⁇ 50% of the dry film thickness. For instance, if the dry film thickness is 100 ⁇ m, the D 50 of the spheres ⁇ 50 ⁇ m.
  • the dry film resulting from application of the coating composition of the invention will also contain microspheres, i.e. the drying of the film does not change the shape of the microspheres significantly.
  • An analysis of the dry film will furthermore allow the skilled person to recognize the microspheres as such.
  • the density of the microspheres may influence the performance of the coating composition.
  • the true density of the microspheres is about 0.01 to 3, e.g. 0.1 to 2.9, such as about 0.2 to 2.8, in particular 0.2 to 0.9.
  • Solid microspheres made from e.g. glass material, or ceramic material typically have a true density in the range of about 2.0 to 2.8.
  • Hollow ceramic microspheres typically have a true density in the range of about 0.6 to 2.5 depending on the thickness of the walls, in some embodiments a true density of about 0.6 to 1.5.
  • polymeric microspheres typically have a true density in the range of about 0.01 to 1.3, e.g. in the range of about 0.01 to 0.9, such as in the range of about 0.2 to 0.9.
  • the microspheres have a particle size distribution such that the D 50 diameter is in the range of about 10 to 120 ⁇ m, such as in the range of about 12 to 100 ⁇ m, e.g. in the range of about 13 to 80 ⁇ m, more particularly in the range of about 15 to 70 ⁇ m.
  • D 50 diameter is understood that 50% of the particles have a diameter of less than the D 50 diameter.
  • microspheres are present in the coating composition of the present invention in an amount suitable to achieve improved corrosion resistance.
  • the microspheres are present in an amount of between about 5 and 50% by solids volume of the mixed paint composition, such as between 6 and 45% by solids volume, e.g. between 7 and 40% by solids volume, more particularly between 8 and 35% by solids volume, such as between 9 and 30% by solids volume, e.g. between 10 and 25% by solids volume, more specifically between 15 and 25% by solids volume.
  • the microspheres are present in an amount of between 2 and 20% by solids volume of the mixed paint composition, such as between 2 and 15% or 5 and 20% by solids volume.
  • the microspheres are present in an amount of less than 18% by weight of the composition, such as less than 15% by weight, e.g. less than 12% by weight of the composition, such as less than 10% by weight, e.g. in the range 0.1 to 9.5% by weight, 0.2 to 9.0% by weight, 0.25 to 8.5% by weight, or 0.3 to 8.0% by weight of the composition.
  • microspheres are not added to the remaining components until after any final grinding.
  • ceramic microspheres is meant to comprise inorganic non-metallic material(s) and/or compositions which comprise e.g. oxides, nitrides, borides, carbides, silicides and sulfides including any combination and/or mixture thereof.
  • Ceramic microspheres can be partially crystalline or fully crystalline.
  • Non-crystalline inorganic glass microspheres are in the context of the present invention not considered ceramic microspheres.
  • metal material is meant to comprise metal(s) or metalloid(s) according to the periodic system of elements including alloys and intermetallics and any combination and/or mixture thereof.
  • Ceramic microspheres according to the present invention may be hollow or solid.
  • Hollow ceramic microspheres include hollow ceramic gas-filled microspheres and hollow ceramic microspheres with thick walls.
  • Ceramic microspheres examples include microspheres based on silica alumina. Ceramic microspheres may be purchased commercially. Suppliers include Cenosphere India, Nippon Steel Sumitomo Metal, Accument Materials and TOLSA.
  • glass is in the context of the present invention meant to refer to glass material in the usual sense of the word.
  • Glass is an amorphous (non-crystalline) material.
  • Typical materials considered to be glass materials by the skilled person include: fused silica glass, vitreous silica glass, soda lime silica glass, sodium borosilicate glass, lead-oxide glass, aluminosilicate glass, calcium sodium silicate, and oxide glass (typically 90% aluminium oxide and 10% germanium oxide).
  • Glass microspheres according to the present invention may be solid. Solid glass microspheres may be purchased commercially. Suppliers include Sovitec and Potter Industries.
  • Polymeric microspheres are microspheres prepared from a polymeric material. Examples include polymethylmetacrylate, cross-linked polymethylmetacrylate, cross-linked polyacrylic ester, polystyrene, polyethylene, polypropylene, polythiophene, acrylonitrile, and melamine resin.
  • Polymeric microspheres may be purchased commercially. Suppliers include Sekisui, Inhance, and Akzo Nobel.
  • the conductive pigment comprised in the coating composition of the present invention may be selected from the group consisting of graphite, carbon black, graphene, aluminium, black iron oxide, antimony-doped tin oxide, mica coated with antimony-doped tin oxide, carbon nanotubes, carbon fibres, and any mixture thereof.
  • the conductive pigment is selected from graphite, carbon black, carbon fibres, antimony-doped tin oxide, carbon nanotubes, graphene, and any mixture thereof.
  • the conductive pigment is selected from graphite, carbon black, carbon nanotubes and any mixture thereof.
  • the conductive pigment is graphite.
  • the conductive pigment is carbon black.
  • graphite when referring to “graphite”, the term is used in the sense that it may still be recognized by the skilled person as graphite per se and not as somehow being incorporated into other materials, in particular zinc, by chemical bonding or otherwise.
  • the conductive pigment such as graphite or carbon black
  • the conductive pigment is in one embodiment present in an amount of between about 0.1 to 6% by solids volume, such as about 0.5 to 5.5% by solids volume, e.g. about 0.7 to 5% by solids volume, more particularly about 0.8 to 4.5% by solids volume, such as about 0.9 to 4.0% by solids volume, e.g. about 1.0 to 3.5% by solids volume, more specifically about 1.0 to 3.0% by solids volume of the coating composition.
  • the conductive pigment such as graphite or carbon black
  • the coating composition of the invention comprises conductive pigment in an amount of less than 12% by weight of the total composition, such as less than 10% by weight, e.g. in the range 0.1 to 9.5% by weight, 0.2 to 9.0% by weight, 0.25 to 8.5% by weight, or 0.3 to 8.0% by weight of the composition.
  • aluminium is intended to cover particulate material, such as silver dollar shaped or leafing and non-leafing flakes.
  • the conductive pigments comprised in the present invention may be directly obtained commercially.
  • Suitable conductive pigments are:
  • the volume ratio between the microspheres and the conductive pigment has an influence on the performance of the coating.
  • the volume ratio microspheres:conductive pigment is in the range 3:1 to 30:1, such as in the range 5:1 to 20:1, e.g. in the range 7:1 to 15:1, particularly in the range 8:1 to 12:1, more particularly in the range 9:1 to 11:1, e.g. 10:1.
  • the binder system comprised in the coating composition of the invention may contain one or more curing agents.
  • the curing agent may advantageously be mixed with the remaining components of the binder system, e.g. an epoxy resin, in situ shortly before being applied.
  • Said remaining components of the binder system are often referred to as the “base component” and in the context of the present invention, when the binder system is not a silicate binder system, the term “base component” is intended to mean the components of the binder system other than the one or more curing agents.
  • another aspect of the invention concerns a kit of parts containing a coating composition as defined herein comprising two or more containers, wherein the binder system is not a silicate binder system and wherein one container contains one or more curing agents and another container contains the base component.
  • the components of the coating composition of the invention as defined herein other than the binder system and curing agent may be contained in either of the two containers of the kit of parts or, possibly, in one or more further containers. Typically, said components will be present in the container containing said base component. Thus, in one embodiment, the components of the coating composition of the invention other than the curing agent are contained in the container containing the base component.
  • a polysiloxane modified binder system comprises an epoxy resin part and an amino-functional polysiloxane and polysiloxane (modified) binder part, which are kept in two separate containers and mixed right before use.
  • the conductive pigment and microspheres are added to the epoxy resin part whereas the zinc particles are added to the polysiloxane resin containing part.
  • the coating composition of the invention may contain two or more separated components.
  • the binder system is a silicate-based binder system
  • the zinc particles may advantageously be mixed with the remaining components of the coating composition in situ shortly before being applied.
  • Said remaining components of the coating composition in silicate-based binder systems are often referred to as the “base component” and in the context of the present invention when the binder system is a silicate-based binder system, the term “base component” is intended to mean the components of the coating composition other than the zinc particles.
  • another aspect of the invention concerns a kit of parts containing a coating composition as defined herein comprising two or more containers, wherein the binder system is a silicate-based binder system and one container contains the zinc particles and another container contains the base component.
  • the binder system is a silicate-based binder system and one container contains the zinc particles and another container contains the base component.
  • the components of the coating composition of the invention as defined herein other than the silicate-based binder system and zinc particles may be contained in either of the two containers of the kit of parts or, possibly, in one or more further containers. Typically, said components will be present in the container containing said base component.
  • the components of the coating composition of the invention other than the zinc particles, wherein the binder system is a silicate-based binder system are contained in the container containing the base component.
  • each of the components a), b), c), and d) as disclosed herein for the paint composition of the invention a number of specific embodiments have been disclosed. It is seriously contemplated to combine each of said specific embodiments for component a) with each of said specific embodiments for component b), each of said specific embodiments for component c), and each of said specific embodiments for component d).
  • one embodiment of the invention concerns a coating composition
  • a coating composition comprising:
  • one embodiment of the invention concerns a coating composition
  • a coating composition comprising:
  • one embodiment of the invention concerns a coating composition
  • a coating composition comprising:
  • one embodiment of the invention concerns a coating composition
  • a coating composition comprising:
  • one embodiment of the invention concerns a coating composition
  • a coating composition comprising:
  • one embodiment of the invention concerns a coating composition
  • a coating composition comprising:
  • one embodiment of the invention concerns a coating composition
  • a coating composition comprising:
  • applying is used in its normal meaning within the paint industry.
  • “applying” is conducted by means of any conventional means, e.g. by brush, by roller, by air-less spraying, by air-spray, by dipping, etc.
  • the commercially most interesting way of “applying” the coating composition is by spraying. Spraying is effected by means of conventional spraying equipment known to the person skilled in the art.
  • the coating is typically applied in a dry film thickness of 5-300 ⁇ m, such as 25-300 ⁇ m or 5-125 ⁇ m.
  • the coating may also be applied in a dry film thickness of 30-300 ⁇ m.
  • the coating composition of the invention may be applied as a single coating.
  • the coating composition of the invention is applied as a single coating.
  • an outer coating composition is subsequently applied onto said zinc-containing coat.
  • the outer coating is typically of a coating composition selected from epoxy-based coating compositions, polyurethane-based coating compositions, acrylic-based coating compositions, polyurea-based coating composition, polysiloxane-based coating compositions and fluoro polymer-based coating compositions.
  • the outer coating is typically applied in a dry film thickness of 30-300 ⁇ m, such as 40-200 ⁇ m or 50-150 ⁇ m.
  • an intermediate coating composition is first subsequently applied onto said zinc-containing coat, whereafter the outer coating is applied onto the intermediate coating.
  • the intermediate coating is typically of a coating composition selected from epoxy-based coating compositions, acrylic-based coating compositions, and polyurethane-based coating compositions.
  • the intermediate coating is typically applied in a dry film thickness of 50-200 ⁇ m.
  • the present invention also provides a coated structure comprising a metal structure having a coating of the coating composition of the invention applied onto at least a part of the metal structure.
  • the present invention also provides a method of coating a metal structure, comprising the steps of applying to at least a part of the structure thereof a layer of a coating composition according to the invention.
  • the present invention also provides a coated structure comprising a metal structure having a first coating of the zinc-containing coating composition defined herein applied onto at least a part of the metal structure in a dry film thickness of 5-300 ⁇ m, such as 25-300 ⁇ m; and an outer coating applied onto said zinc-containing coating in a dry film thickness of 30-300 ⁇ m, such as 30-200 ⁇ m.
  • the outer coating is of a coating composition selected from epoxy-based coating compositions, polyurethane-based coating compositions, acrylic-based coating compositions, polyurea-based coating composition, polysiloxane-based coating compositions and fluoro polymer-based coating compositions.
  • an intermediate coating has been applied onto said zinc-containing coating in a dry film thickness of 50-200 ⁇ m before application of the outer coating composition.
  • the intermediate coating is of a coating composition selected from epoxy-based coating compositions, acrylic-based coating compositions, and polyurethane-based coating compositions.
  • the metal structure is typically selected from bridges, containers, refineries, petrochemical industry, power-plants, storage tanks, cranes, windmills, steel structures part of civil structures e.g. airports, stadia and tall buildings, or fixed or floating offshore equipment, e.g. for the oil and gas industry such as oil rigs.
  • the paint may be prepared by any suitable technique that is commonly used within the field of paint production.
  • the various constituents may be mixed together using a high speed disperser, a ball mill, a pearl mill, a three-roll mill etc.
  • the paints according to the invention may be filtrated using bag filters, patron filters, wire gap filters, wedge wire filters, metal edge filters, EGLM turnoclean filters (ex. Cuno), DELTA strain filters (ex. Cuno), and Jenag Strainer filters (ex. Jenag), or by vibration filtration.
  • the solid components of the coating composition are mixed and ground.
  • the microspheres are advantageously not included until after the grinding has taken place.
  • the microspheres are included in the paint composition of the invention after any grinding of the remaining paint components.
  • the invention comprises a paint composition obtainable by including the microspheres after any grinding of the remaining paint components.
  • the coating composition may be prepared as a one component coating or by mixing two or more components e.g. two pre-mixtures, one pre-mixture comprising the based component and one pre-mixture comprising the zinc particles. Or as a three component system where one pre-mixture comprises the base component, one pre-mixture comprises the zinc particles and a third container comprises any additional component(s).
  • microspheres and the conductive pigment may be added, together or separately, to any of the components in a coating composition prepared from two or more components. They are, however, preferably added to the binder system.
  • Steel panels are coated with 1 ⁇ 70 ⁇ m of the paint to be tested.
  • the steel panels (10 ⁇ 15 cm ⁇ 1.6 mm) are cold rolled mild steel, abrasive blasted to Sa 21 ⁇ 2 (ISO 8501-1), with a surface profile equivalent to BN 9 (Rugotest No. 3). After the samples have been coated the panels are conditioned at a temperature of 23 ⁇ 2° C. and 50 ⁇ 5% relative humidity for a period of 7 days.
  • the specimens shall be viewed with a stereo microscope at 30 ⁇ magnification. Following information shall be recorded:
  • Salt spray test was performed according to ASTM B 117 (ISO 9227). This is a test for evaluating corrosion resistance in salt spray or reproducing corrosion that occurs in an atmosphere containing salt spray or splash (constant spray with 5% NaCl solution at 35° C.).
  • a scribe was made on each panel according to ISO 12944.
  • the paint around the scribe (approximately 1.5-2 cm on each side of the scribe) on the panel was removed e.g. by an air chisel.
  • Component 1 was prepared in the following way: The epoxy resin(s), reactive epoxy diluent, conductive pigment, filler, wetting agent, dispersing agent, scavenger, rheologic and thickening agent and 60% of the solvents (xylene:n-butanol 3:1 wt) were premixed on a high speed mixer equipped with an impeller disc (90 mm in diameter) in a 2.5 litre can for 15 minutes at 1000 rpm. The zinc particles were then added and mixed for about 15 minutes at 2000 rpm. Microspheres were added under slow stirring together with 30% of the solvents. The remaining 10% of solvent was then added.
  • the epoxy resin(s), reactive epoxy diluent, conductive pigment, filler, wetting agent, dispersing agent, scavenger, rheologic and thickening agent and 60% of the solvents (xylene:n-butanol 3:1 wt) were premixed on a high speed mixer equipped with an impeller disc (90 mm in diameter) in
  • Component 2 was Prepared in the Following Way:
  • the polyaminoamide, defoamer, thixotropic agent, and bisphenol A were mixed with 75% of the solvent. After 60 hours at 23° C. the epoxy accelerator and the remaining solvent were added on a high speed mixer equipped with an impeller disc (90 mm in diameter) in a 2.5 litre can for 15 minutes at 1000 rpm.
  • component 2 was added to component 1 and the paint composition was mixed to a homogenous mixture.
  • Ethyl-silicate and isopropanol were mixed in a suitable can and hydrochloric acid solution was added slowly under agitation for 1 hour.
  • the intermediate base xylene, pre-hydrolysed ethyl silicate (around 30-40%), organo clay, wetting and suspending agent, silica aerogel and graphite (or carbon black or other conductive pigments) were pre-mixed on a Diaf dissolver equipped with an impeller disc (90 mm in diameter) in a 4 litre plastic can for 15 minutes at 1500 rpm. Fineness of grind is checked. If fineness is below or equal 60 ⁇ m then let down is added. Let down is based on 60-70% of pre-hydrolysed ethyl silicate, isopropanol and aromatic hydrocarbon solvent. The mixture was dispersed during 5 min at 1000 rpm.
  • Last step was addition of microspheres, keeping the can completely covered when stirring to avoid loss of spheres. Stirred at 1000 rpm until homogenization.
  • Zinc silicate coatings are known in the art to exhibit very good anticorrosive protection. Thus, the advantages of the present invention in terms of improvement in corrosion protection will only be apparent on a long time scale. However, very preliminary observations of the coatings according to the invention and the reference coatings indicate that coatings according to the invention show good anticorrosive effect and better performance than reference coatings (indicated by white salt formation in the test panels having had the coating of the invention applied to them).
  • Component 1 was Prepared in the Following Way:
  • Last step was the addition of microspheres, keeping the can completely covered when stirring to avoid loss of spheres.
  • the microspheres were added under slow stirring at 600 rpm until homogenization.
  • Component 2 was Prepared in the Following Way:
  • the amino functional siloxane resin and polysiloxane were premixed on a high speed mixer equipped with an impeller disc (90 mm in diameter) in a 2 litre can for 15 minutes at 1200 rpm.
  • component 2 was added to component 1 and the paint composition was mixed to a homogenous mixture.
  • the panel numbers for both the model paint and the reference paint were randomly assigned. The three panel average of each measurement for each coating provides the conclusion that the model paint outperforms the reference.
  • Component 1 was Prepared in the Following Way:
  • the hydroxyfunctional acrylic resin solution 60-70%), wetting and dispersing agent(s), rheological agent (amide wax), corrosion inhibitor, zinc dust and graphite (or carbon black or other conductive pigments) and 20% of the aromatic hydrocarbon solvents were premixed on a high speed mixer equipped with an impeller disc (90 mm in diameter) in a 4 litre metallic can for 15 minutes at 1500 rpm until 60-70° C. The temperature was kept in this range for 10 minutes. Subsequently, fineness was checked. If below or equal to 60 ⁇ m, the let-down can be added.
  • microspheres or barite/calcium carbonate
  • the remaining solvent (2%) was added and dispersed at 1000 rpm until homogenization.
  • component 2 polyisocyanate
  • component 1 mixture ratio 9:1, component 1: component 2
  • the step of adding conductive pigment and/or glass spheres was omitted.

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